1. Technology Introduction & Benefits

Transcription

1 Macromelt Molding

2 Agenda 1. Technology Introduction & Benefits 2. Product Range 3. Typical Project Procedure 4. Equipment 5. Design Guidelines 6. Contacts & Further Information

3 1. Technology Introduction & Benefits What is Macromelt Molding? Macromelt Molding = Low Pressure, Adhesive, Injection Molding A process innovation positioned between casting and injection molding technologies Injection Molding pressure Macromelt Molding Casting cycle time

4 1. Technology Introduction & Benefits Technology Background High performance polyamide hotmelts Solvent free, no safety labels >50% of raw materials are based on renewables (vegetable oils) Long shelf life (2+ years) Standard colors: black and amber

5 1. Technology Introduction & Benefits Typical Applications 1. Encapsulation of Connectors To protect against heat, water, dust To obtain strain relief 2. Grommets / Sockets To obtain strain relief To fix molded part in correct position 3. Encapsulation of Electronic Devices To protect against heat, water, dust

6 1. Technology Introduction & Benefits And Many Other Applications... Medical connector Socket for heating unit Induction electronic switch Signal light for filling quantities Micro switches Control unit for small E-Motors

7 1. Technology Introduction & Benefits Technical Features Low Pressure Injection pressure between 2 and 40 bar No damage of electronic parts Molds can be made of aluminum (low costs) Adhesive To manufacture electrical devices which are water tight To fix molded part in correct position To obtain strain relief on cables Products based on natural raw materials environmentally compatible Injection Molding Cycle times typically between 10 and 50 seconds Allows higher output than with casting applications Clean and simple to use process

8 1. Technology Introduction & Benefits Benefits Cost Savings Molds can be made of aluminum instead of steel Less adhesive needed compared to traditional casting Saves energy by eliminating the heat curing process Time Savings Fast cycle times (10 to 50 seconds); no extra time for curing Simple and clean process with low machine maintenance needs Production Space Savings No space needed for case storage and curing

9 2. Product Range Our Standard Product Range Properties Macromelt OM 652/657 Macromelt OM 633/638 Macromelt OM 673/678 Technology polyamide polyamide polyamide Color amber/black amber/black amber/black Service temperature range in C -40 to to to +140 Cold flexibility in C Application temperature range in C +180 to to to +240 Shore hardness A 77 A 90 A 90 Adhesion (example: adhesion to PA) Elongation at break in % Remarks UL94-V0, Good cold flexibility UL94-V0 UL94-V0

10 2. Product Range Colors Henkel standard colors are amber or black Via colored master batches* you can achieve almost every color you need * Available from selected molding partners

11 2. Product Range Order Information for Direct Customers Product Name Color Packaging Henkel IDH Number Macromelt OM 652 amber Macromelt OM 657 black Macromelt OM 633 amber Macromelt OM 638 black Macromelt OM 673 amber Macromelt OM 678 black

12 2. Product Range Our Standard Product Range Properties Macromelt OM 652/657 Macromelt OM 633/638 Macromelt OM 673/678 Macromelt Q 5375 Technology polyamide polyamide polyamide polyolefin Color amber/black amber/black amber/black white-light-beige Service temperature range in C -40 to to to to +85 Cold flexibility in C Application temperature range in C +180 to to to to +200 Shore hardness A 77 A 90 A 90 A 50 Adhesion (example: adhesion to PA) Elongation at break in % Remarks UL94-V0, Good cold flexibility UL94-V0 UL94-V0 superior adhesion to PP, PE, PET

13 2. Product Range Our Product Innovations: Macromelt OM 653 high moisture resistance Applications Any kind of electronics (e.g. circuit boards, electronic components, sensors, control systems) which should be protected against environmental influences like the 85/85 test (85 C; 85% humidity, h) Characteristics Suitable for a temperature range of -40 C to +100 C Adheres to polar plastic like PA, ABS and PVC Maintains stable mechanical values after 85/85 test

14 2. Product Range Our Product Innovations: Macromelt 6208 / 6208 S RTI listed Applications Any kind of electronics (e.g. circuit boards, electronic components, sensors, control systems) which need to be protected against environmental conditions. Characteristics Suitable for a temperature range of -40 C to +100 C Adheres to polar plastic like PA, ABS and PVC RTI 95 C Macromelt 6208 S fully UL listed with HAI, HWI, RTI, CTI, UL94

15 2. Product Range Our Product Innovations: Macromelt OM 641 / OM 646 for big parts Applications Any kind of electronics (e.g. circuit boards, electronic components, sensors, control systems) which need to be protected against environmental conditions. Is often used for bigger parts because of the high elongation at break. Characteristics Suitable for a temperature range of -40 C to +130 C Adheres to polar plastic like PA, ABS and PVC Elongation at break 650 %

16 2. Product Range Our Product Innovations: Macromelt OM 648 UV stabilized Applications Any kind of electronics (e.g. circuit boards, electronic components, sensors, control systems) which need to be protected against weather and UV-radiation. Typical examples are grommets and plugs molded for solar connection cables and the molding of solar connection boxes. Characteristics UV-stabilized and weatherproof Adaptable to optical requirements Process approved and clean handling Eliminates the application of plastic housings due to its plastic like attributes Shorten the cycle times for the injection-molding compared to 2-component casting

17 2. Product Range Our Product Innovations: Macromelt OM 730 reactive PA, high temp. resistance Applications Any kind of electronics (e.g. circuit boards, electronic components, sensors, control systems) which need to be protected against environmental conditions and high temperatures Foil bag adhesive applicator, Cleaner: Purmelt Cleaner 2 Characteristics Remains inherently stable up to more than +200 C Short-term stability up to +270 C Applicable in processes with reflow-soldering

18 2. Product Range Our Product Innovations Polyamide Basis: Properties Macromelt OM 653 Macromelt 6208/6208 S Macromelt OM 641/646 Macromelt OM 648 Color amber amber/black amber/black black Service temperature range in C -40 to to to to +130 Cold flexibility in C Application temperature range in C +180 to to to to +240 Shore hardness A 77 A 82 A 92 A 93 Adhesion (example: adhesion to PA) Elongation at break in % / Remarks - UL94-V0 UL94-V0 -

19 2. Product Range Our Product Innovation on PAX Hotmelt Basis: Properties Color Service temperature range in C Cold flexibility in C Application temperature range in C Shore hardness Adhesion (example: adhesion to PA) Elongation at break in % Macromelt OM 730 amber -20 to to +240 D

20 2. Product Range Colors Henkel standard colors are amber or black Via colored master batches* you can achieve almost every color you need * Available from selected molding partners

21 2. Product Range Order Information for Direct Customers Product Name Color Packaging Henkel IDH Number Macromelt OM 652 amber Macromelt OM 657 black Macromelt OM 633 amber Macromelt OM 638 black Macromelt OM 673 amber Macromelt OM 678 black Macromelt Q 5375 white-light-beige 25 kg box Macromelt OM 653 amber Macromelt 6208 amber Macromelt 6208 S black Macromelt OM 641 amber Macromelt OM 646 black Macromelt OM 648 black Macromelt OM 730 amber 12 kg box

22 3. Typical Project Procedure 1. Collect the requirements Temperatures in the final application Material(s) which have to be over-molded Resistance against chemicals These three parameters are most important to determine the suitable adhesive(s)! 2. Conduct spot test on the parts for a first impression of the adhesion

23 3. Typical Project Procedure 3. Test procedure (example) Construction of trial mold for the production of professional samples. Different adhesives can be tried out. The tests need to be run and evaluated by the customer to make sure all requirements are fulfilled. In case the tests are not successful a different adhesive or an improved design can be a solution.

24 3. Typical Project Procedure 4. Production After a successful test procedure the right design and the right adhesive will be known. With the design in mind it is possible to calculate the possible number of cavities of the mold. With the production figures of the customer, it will be possible to find the right molding machine. After a successful test procedure, the customer will have the confidence that all requirements are fulfilled.

25 4. Equipment Manual Hand Gun Typical usage Trials or small production Typical output 500 to parts/year Typical part size 1-20 gr. Costs Appr

26 4. Equipment Automated Molding Machine Typical usage Mid-size to high volume production Typical output to parts/year Typical part size 1-50 gr. Costs Appr to Mold C-Frame with Cylinder Hose Tank The The Macromelt Macromelt granulates granulates are are melted melted in in the the tank. tank. A gear gear pump pump builds builds the the pressure pressure and and the the material material flows flows through through the the heated heated hose hose and and the the injection injection head head into into the the mould. mould. The The Cylinder Cylinder of of the the C-frame C-frame closes closes and and opens opens the the mold. mold. Injection Head Gear Pump Motor

27 4. Equipment Examples of Automated Molding Machines

28 4. Equipment Molds Material Usually aluminum Easy to mill, drill, erode Good release of the molded pieces Steel inserts recommended in contact areas to plastic or metal parts Lifetime Very long, as Macromelt is not abrasive nor corrosive Costs Appr to , depending on Size & material Number of cavities Ejectors, grade of automation

29 5. Design Guidelines Overmolding For tight connections during lifetime of parts, adhesive must completely cover connector and cable (pic.1), using adhesion plus shrinkage force of Macromelt If there is not enough space outside, create an inner shrinkage area (pic. 2) Picture 1 Picture 2

30 5. Design Guidelines Overmolding Avoid connections without shrinkage area (pic. 3) After temperature cycles, Macromelt might release from the parts (pic. 4) Picture 3 Picture 4 X

31 5. Design Guidelines Radius and Release Angle Avoid rectangular designs (pic. 5) Design corners with a radius for better flow of adhesive and easier release; release angles help to remove parts more easily out of the mold (pic. 6) Picture 5 Picture 6 X

32 5. Design Guidelines Same Amount of Material Flexible parts need same amount of material on both sides (pic. 7) With different amounts of adhesives (pic. 8), the shrinkage force will bend the parts (pic. 9) Picture 8 Picture 7 XPicture 9

33 5. Design Guidelines Grommets Design a bending area to have the bending point away from the sealing area (pic. 10) For water tight grommets each single cable needs to be covered with adhesive (pic. 11) Picture 10 Picture 11

34 5. Design Guidelines Venting To avoid trapped air allow venting of the mould by inserts like ejectors, marking inlets or other inlets

35 5. Design Guidelines Ejection Eject parts on solid areas like connectors Use large area ejectors when pushing parts on the adhesive to spread the forces